Author Topic: Sherpa T M92  (Read 2818 times)

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Offline Short Stuff

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Sherpa T M92
« on: September 26, 2016, 12:38:20 PM »

A long time ago (when we had paper money, shops shut at midday om Saturdays and I had black hair), I used to knock around with a guy named Justin. Justin used to compete in club trials on a Montessa Cota 172, and I used to follow him around on his dad's Sherpa T 350.  I enjoyed that bike cos' the seat was so low that I could touch the ground with ease (I was short back then too!)  Those bikes were so quiet, that we would walk them down to the cutting under Mont Albert Road (part of the old Kew railway) and ride for hours without alerting the attention of anyone.

I caught up with Justin at the 2015 AMTRA HCR, I asked about the Sherpa and he advise that it was lost in a fire some years ago.  When I got the resto bug, I always thought that, one day, I'd try and do one on a Sherpa.  Well, that day has come.  She's not pretty, but a good base to start with.





I started pulling it down a month (or so) ago, and with so few parts, pulling the Taco down was a relatively simple and quick job.





The only real problem that I encountered so far, was that the swing-arm axle and bushes had become one and were corroded together, which required cutting through the axle to remove.  But aside from that, I was pleased to see so many original Bultaco bolts still in place and in good condition, along with so many other parts in an un-molested state!

With the frame and swing-arm in two separate pieces, I set off to get them sandblasted and officially start the re-build.

2 coats of primer, 2 top-coats and a clear coat (along with a small repair) and the frame was goo to go.






Offline Short Stuff

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Re: Sherpa T M92
« Reply #1 on: September 26, 2016, 12:39:31 PM »
I then set to cleaning and polishing up the triple clamps.  looks like they had been previously painted (from factory?), so I bead-blasted them and gave them a buff.









The fork tubes were next and unfortunately they had some pretty deep gouges which I wasn't to keen to try and go too deep to repair, so I'll chalk this up to 'patina'.







The forks themselves were treated to fresh oil and seals (by Paul at Ridewell), and I started to zinc plate the pinch bolts for the wheel axle and lower triple.




Offline Short Stuff

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Re: Sherpa T M92
« Reply #2 on: September 26, 2016, 12:40:49 PM »
The rear shocks became a bit of a disaster!  The bike was fitted with Boge-Mullholand shocks, but they proved to be not worth re-building as the magnesium top-caps crumbled when removed, exposing a crack through the thread in the shock body.  Paul spent a fair bit of time mucking around with this, until he suggested giving up and built me a set of Konis out of NOS parts.  I agreed, and now I have a set of fully adjustable,  re-buildable Konis!

So, I spent the last weekend putting all this together and I'm pretty happy with the result so far.



















So, STAGE ONE of the build (sprung frame) is basically complete.  Next stage is/are the wheels, which are underway!

Offline kdx Geoff

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Re: Sherpa T M92
« Reply #3 on: September 26, 2016, 06:50:47 PM »

Looks great Serge  :)
Buying kdx air cooled drum brake unitrak bikes and parts

Offline TTezza

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Re: Sherpa T M92
« Reply #4 on: September 27, 2016, 12:53:39 AM »
Another Bully brought back to life, well done  ???
« Last Edit: September 27, 2016, 10:12:26 AM by TTezza »

Offline the stig

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Re: Sherpa T M92
« Reply #5 on: September 27, 2016, 07:36:13 AM »


      Nice Job Serge Fun bike or Garage Queen...

      The Stig

Offline Short Stuff

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Re: Sherpa T M92
« Reply #6 on: September 27, 2016, 08:28:11 AM »


      Nice Job Serge Fun bike or Garage Queen...

      The Stig

Definitely a rider!

Offline the stig

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Re: Sherpa T M92
« Reply #7 on: September 27, 2016, 07:57:58 PM »


    Good i am doing a TY 250 up   s  l  o  w  l  y    still waiting for a few bits to come up on easybuy..

     Then Stig

Offline fred99999au

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Re: Sherpa T M92
« Reply #8 on: September 27, 2016, 08:28:34 PM »
That is coming up really nice, mate. Cant wait to see it finished, although the starting pic looked like it just needed tyre pressure and a seatcover.

Offline the stig

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Re: Sherpa T M92
« Reply #9 on: September 28, 2016, 01:44:02 PM »
That is coming up really nice, mate. Cant wait to see it finished, although the starting pic looked like it just needed tyre pressure and a seatcover.

     Yes Fred  my Resto  come in about 6 milk crates

     The stig

Offline fred99999au

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Re: Sherpa T M92
« Reply #10 on: September 28, 2016, 06:19:58 PM »
I have an IT250K like that.

Offline Short Stuff

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Re: Sherpa T M92
« Reply #11 on: October 30, 2016, 02:13:16 PM »
ROLLING (and Stopping)!

A major point in any resto (I believe), is getting the bike to a rolling state, and I got there today!



But I'll take a step back.

I suspected that the wheels on this bike would come up looking alright.  The hubs looked good (inside and out), the spokes are all stainess and the rims (although grubby and scratched), had potntial.  I started with the front wheel and pulled it down.  There were 3 rouge spokes laced in (that would have to be replaced) and I snapped another two when removing them, so that was a total of 5.  Fortunately, they are still available to purchase individually, so no problems there.  The nipples were all munted during removal, so I was up for a full set of them.

With all the bits separated, I poliched and painted the front hub (which came up a treat).  I buffed up all the spokes and they came up looking better than the NOS replacement ones.  I polished the rim and although it looked good, I knew it could look better, so I gave it to Dave at Mid Metal Polishing andhe finished it off.

I took the whole shooting match around to Phil ant Lightfoot and he put it together, including knocking out a few flat spots in the rim.  I was very happy with the result.







I zinc plated and/or polished all the spacers, nuts, levers, brake cam, brake plate etc. fitted a new tyre, complete with new rim-lock and rim-tape and tube, then bolted it onto the bike for a finished product!



Before and after.




Offline Short Stuff

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Re: Sherpa T M92
« Reply #12 on: October 30, 2016, 02:15:58 PM »
Next on the agenda was the rear wheel.

I followed the same process as before and pulled the wheel down.  This time, I snapped 3 spokes but all the nipples came off well.  Hub was painted and polished, spokes were buffed and I just gave the rim straight to Dave (no point wasting time!).  There was a nasty 'chunk' taken out of the rim, which Dave managed to smooth out and make it almost invisible.

Berore


During


After




This time, I gave the bits to Paul at Ridewell Motorcycles to assemble.  And along with new rim-locks, tubes, tape and tyre he gave me back the wheel, which looked grouse!  

Once again, I plated everything that needed plating, polished everything that needed poishing, dropped in some new bearings, bolted on a new sprocket, hooked up the brake bits and took the bike off the static stand.










Offline Short Stuff

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Re: Sherpa T M92
« Reply #13 on: October 30, 2016, 02:17:20 PM »
The Changing of the Guard

The guards on these bikes should be a beautiful, polished aluminium and although they're are available ('NOS') out of Spain and England', I haven't worked out which one of my daughters I'm gonna sell to buy a set of them!  Consequently, I'm fitting a set of Gonelli plastic guards (apparently standard equiptment on later model Sherpas?)  It was always my intention for this bike to be a 'rider', so having the cheaper set of guards eliminates the fear of stuffing a good set.  having said that, I fully intend to obtain some ally guards for when I just want the bike to look pretty.  If anyone can give me a lead as to where to get these locally (Aus), I'd be happy to know.

The bike had some Gerry-built front guard stays when I got it, so I had to get a set of 'NOS' ones out of spain, which seemed to take forever to arrive.  They bolted straight on all I needed to do was position the guard and drill 4 holes to mount it.  I don't like the look of the all-in-one guard and flap, but for around $50.00 who's quibbling!





The rear guard is a bit more of an issue.  The Gonelli units are very short and the Sherpa only has 3 mounting points (2 at the rear hoop and one down by the swing-arm.  If the guard is fitted using the lower mount, then the guard just protrudes past the rear frame hoop and looks silly.  If it's fitted just using the 2 rear mounts, then it has no stability and will just flap around.  It was suggested to make an extra mounting bracket and bolt it between this and the rear mounts, which is what I chose to do.

Using a lenghth of 20mm aluminium flat, I bent a curve and bolted it between the side panel mounts.  Then I could simply drill 2 new holes and have the guard mounted at 4 points and have enough guard hanging out the back to vaugley replicate the profile of the original guard. Only problem with this is that the area between the end of the guard and the swing arm is exposed to the perils of riding.  To 'bridge-the-gap', I fashioned a piece of an old Preston Petty guard I had, to create an extension.  The Gonelli guard is now sandwiched between the extension and the new mounting bracket, and then it's bolted to the lower mounting point too.  The whole shooting match can be removed as one unit, by simply undoing the original 3 mounting bolts and the 2 side cover screws, leaving the new bracket, extension and guard bolted together!  Fortunately, the side cover hides my atrocious attempts at engineering and fabrication!









The end result (I think) is a servicable guard that closely resembles the 'style'of the original.  And as I said before, if I drop it and stuff the guard, it's an inexpensive fix!

So now, the motor gets up onto the bench....

Offline shelpi

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Re: Sherpa T M92
« Reply #14 on: October 30, 2016, 02:34:48 PM »
Great stuff Short Stuff

Offline 80-85 husky

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Re: Sherpa T M92
« Reply #15 on: October 30, 2016, 02:52:37 PM »
the motor should be good as gold bar the seals Serge, I don't think much ever goes wrong unless its been run unfiltered or no oiled. polish those cases.... 8)

Offline tony27

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Re: Sherpa T M92
« Reply #16 on: October 30, 2016, 03:06:40 PM »
I think your extra mount looks good, only suggestion would be to swap the guards around at the new mount so that any mud/water follows down rather than over the lower guard & onto the front of the swingarm

Offline Short Stuff

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Re: Sherpa T M92
« Reply #17 on: October 30, 2016, 03:48:19 PM »
I think your extra mount looks good, only suggestion would be to swap the guards around at the new mount so that any mud/water follows down rather than over the lower guard & onto the front of the swingarm

Yes, I thought of that tony27, but unfortunately the black guard (extension) is slightly narrower than the white guard and it just didnt sit right.

I haven't quite finished the mount yet, so a bead of silicone might be the go.

Thanks for your advise.

Offline Moto

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Re: Sherpa T M92
« Reply #18 on: October 30, 2016, 06:14:54 PM »
The plastic mudguards are a problem on these models.On the front guard I cut the plastic mudflap off.I found that when the forks are at full compression the flap would scrape on rocks etc(I think it actually split)cut it off neatly,no more problems.
On rear to extend the length,l had a broken piece of original guard,most originals are broken at the rear when the bike was flipped or thrown away.The lower part is usually undamaged.I cut it so it joins neatly to the plastic guard and still use the original lower mount.All polished up it looks great.You might get a piece at a swap or Peter S may have a piece from a wreck.
You are doing a great job with the bike.I am currently building a set of wheels for my Mk 12.Wheels are a big job and take a lot of time and patience.
« Last Edit: October 30, 2016, 06:17:32 PM by Moto »

Offline David Lahey

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Re: Sherpa T M92
« Reply #19 on: October 30, 2016, 09:22:14 PM »
Rear Gonellis are available in two lengths. The full length version is made to be the right length to reach from just above the swingarm pivot and provide just the right amount of overhang at the rear
previous pseudonym feetupfun

Offline Short Stuff

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Re: Sherpa T M92
« Reply #20 on: December 26, 2016, 12:41:26 PM »
UPDATE: 

Given that the frame was now rolling, it was time to get the engine up on the bench and make a start on it. Despite (potentially) years of neglect, the power plant didn't look too bad.  A few bent and cracked fins and some minor scrapes and dents in the cases, but nothing to get too stressed over.









Before I pulled it out of the bike, I made sure it had spark (which it did), so theoretically when I put it all back together, it should still spark.  Happy with that knowledge, I tried to remove the sump plug, but it was stuck fast and the bolt head was pretty ratty.  No probs I thought, I'll disassemble from the top and flip it to drain the oil and get a better attack at the plug.  So I unbolted the head and that looked pretty good.  Slid the barrel off and despite a bit of water marking on the lower region of the bore, that too looked good.  Piston showed no signs of wear or gouging, so still happy with the progress.  Studs were looking a bit rusty, but a wire brushing would soon sort them out. 








 OK, time to flip.......and my heart sank!  A 50 mm crack in the case revealed itself when I cleaned away the grunge festooning the bottom of the engine.



Panicking, I sent a photo to Paul (Ridewell Motorcycles), and asked if this was terminal.  His response was, "Nah, she'll be right!"  Buoyed by this, I continued on my merry way and pulled it down to present it to him for welding.

Obviously, to repair this crack, it was necessary to split the cases, which meant the Sherpa was getting new crank and gear-box bearings (regardless of wether it needed them or not).  So when the repair was done, he gave me back the cases and side covers and they were duly polished and returned.  meanwhile, I took the stator to an auto-elect mate of mine and had some new wires soldered to the coils, as the originals were not only crispy and stiff, but had been butchered over the years. The stator was returned to Paul and along with a new gasket kit, the bottom end was rebuilt.

Closer inspection of top-end components revealed that all was in great shape, so a light hone was all that was needed (along with bead-blasting and painting) before that went together and completed the re-build.








Offline Short Stuff

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Re: Sherpa T M92
« Reply #21 on: December 26, 2016, 12:42:14 PM »
And so now, with engine together, it was time to put it back in the frame and make it a MOTOR bike.

I was starting to believe the bike would be a fairly light machine, until I wrestled the noise maker in!  It feels as though the engine weighs about as much as the rest of the bike.  Nevertheless, in it went, but not before mounting the kick-starter (which had been re-plated, new pivot kit and rubber), gear lever (which got the same treatment) and exhaust manifold (which was also re-plated).







Melbourne's hot weather (and Christmas) has limited my shed time, but I managed to get an hour or two to bolt on some more bits.  Muffler was blasted and re-painted, header pipe was polished and all put together with new springs and coupling.  Clutch arm was re-plated and installed with new cable and return spring etc.  Terminal block was polished and mounted with fresh hardware, along with the coil and checked for spark (which it has, phew!)  I'm not over-happy with the way the wiring is currently sitting, but I'll re-visit this on a cooler day.

So all-in-all, I'm pretty happy with the progress thus far.  Next job is to give the carbie and overhaul and mount that.  Then with throttle and air box pipe in place, we should be ready to kick her over!








Offline Short Stuff

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Re: Sherpa T M92
« Reply #22 on: December 26, 2016, 12:43:15 PM »











Offline 80-85 husky

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Re: Sherpa T M92
« Reply #23 on: December 26, 2016, 01:46:04 PM »
nice work, she looks great. have you got the second banana muffler?

you may need to scrape the connections to get a good earth. you wont know till you try to fire her up. if its missing and farting, it may be a poor earth.

also beware of the reverse running feature, make sure the 5000 year old ming vase isn't behind the bike when you go to ride it....


Offline David Lahey

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Re: Sherpa T M92
« Reply #24 on: December 26, 2016, 04:03:27 PM »
Looks very nice.
For next time, the motor is a lot lighter without the flywheels and cylinder in place. I always do the final assembly with the motor in the frame. Bultaco motors in general are quite a light motor for the era, with the exception of 325cc Bultaco trials motors with their huge flywheels. 
previous pseudonym feetupfun

Offline Short Stuff

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Re: Sherpa T M92
« Reply #25 on: February 12, 2017, 05:08:27 PM »
THE MISSING LINK:

The final piece of the engine puzzle (the carby), has finally been sorted!



It looks like the slide may have been dropped at some stage, as there was a fine 'ridge' on the bottom egde which was catching inside the bore of the carb and causing it to bind.  So Paul plished it out with a bit of fine wet n' dry, untill the the side slid happily all the way up and down.  I finished giving it a good clean, then bolted it onto the manifold (with new gaskets and hardware), hooked on the new airbox-carby tube, oiled up and inserted a new air filter, hooked up and plumbed a new throttle cable and slipped on some new grips.

I then gave the bike back to Paul and got him to check timing and points gap, and check all the carbie settings, then........

https://youtu.be/DcM1A1lAYkU

Offline Short Stuff

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Re: Sherpa T M92
« Reply #26 on: March 10, 2017, 08:02:37 PM »
Ooohh!!




Offline 80-85 husky

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Re: Sherpa T M92
« Reply #27 on: March 10, 2017, 09:23:33 PM »
ohhhyeeaaahh, got to love that sherpa style

Offline bigthumpa

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Re: Sherpa T M92
« Reply #28 on: March 10, 2017, 10:01:45 PM »
Very nice job! I have still got my Dad's model 92 in the shed, bought new in 1973 from Lloyd Chapman Motorcycles. Still run great although completely unrestored.

Offline Short Stuff

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Re: Sherpa T M92
« Reply #29 on: March 10, 2017, 10:27:40 PM »
Very nice job! I have still got my Dad's model 92 in the shed, bought new in 1973 from Lloyd Chapman Motorcycles. Still run great although completely unrestored.

I'd like to see that.  ;)

Offline Short Stuff

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Re: Sherpa T M92
« Reply #30 on: March 11, 2017, 06:38:30 PM »
TANKS A LOT!

The tank that came with this bike had some weird, hippy sh!t paint job that someone had done over the years.  The tank itself looked OK, but was festooned with muck on the underside, where it had been leaking for who know how many years.  So, over Xmas, I cleaned and de-greased it and discovered that it was actually in pretty good shape.  It did, however, leak and so the first job was to attempt to seal it.  I did some investigation and found the KBS system was getting good results, so I bought a kit.  I followed the 3 stage set of instructions and after waiting for the appropriate period of time, I re-filled the tank and shook it around and....... no leaks!




Happy with this result, I started to sand the tank and remove the old paint.





Then I filled and sanded the major holes and cracks and spray puttied it.






Then it was ready for priming.





And then ready for top coating.



In the mean time, I had been working on replicating the tank graphics and printed out a set of stickers fro the tank, along with the round logos.



And when they were done, I stuck them onto the tank and gave the tank to Darren, who passed it onto a mate of his and he blew some coats of clear across the whole unit.  The clear helped to conseal all the attrocities I had committed and gave the tank a brilliant, glossy finish and sealed the stickers at the same time.





Now I just have to man up and put some fuel in it (and hope like hell it doesn't decide to start leaking).

Offline Short Stuff

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Re: Sherpa T M92
« Reply #31 on: March 11, 2017, 06:39:02 PM »
TAKE A SEAT!

The seat that was on the bike was munted.  The cover was as hard and brittle as old wood, the foam was crumbling away and it didn't even feel like it had a base.  As I was cleaning the tank, I discovered that a poor fibreglass repair job had hidden the 3 nuts holding the seat in place.  I cut away the glass, undid the nuts and the seat (such as it was) fell away from the tank.

The seat base was in about 10 pieces (I've lost the photo), [I found the photo:] so I glued them altogether



and then layed a sheet of fibre glass top and bottom.





Cut away the excess mat and the end result was a firm, servicable base.



I blew a coat of paint over the base and bought a fresh foam and cover for it, then assemble the whole shooting match.



Bolted the seat onto the tank and it all looks great!
« Last Edit: March 12, 2017, 12:05:56 PM by Short Stuff »

Offline Short Stuff

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Re: Sherpa T M92
« Reply #32 on: March 11, 2017, 06:39:39 PM »
And so now, with a few minor adjustments and tasks to complete, I'm about ready to say the Taco is finished!




Offline 80-85 husky

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Re: Sherpa T M92
« Reply #33 on: March 11, 2017, 07:08:43 PM »
now for some feet up top gear slides and some km long wheelies ;) love that bulty power

Offline tony27

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Re: Sherpa T M92
« Reply #34 on: March 11, 2017, 07:22:54 PM »
You have to be pleased with the results.
An absolute beauty

Offline shelpi

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Re: Sherpa T M92
« Reply #35 on: March 26, 2017, 10:39:57 AM »
Excellent

Offline Hoony

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Re: Sherpa T M92
« Reply #36 on: March 26, 2017, 11:29:10 AM »
awesome build ...really enjoyed reading this
Long time Honda Fan, but all bike nut in general, Big Bore 2 stroke fan.    http://www.youtube.com/watch?v=XJoKP6MawYI
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Offline TTezza

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Re: Sherpa T M92
« Reply #37 on: March 26, 2017, 09:28:21 PM »
Top job, well done SS  :)